PROJECT
Industrial robotic arm with hand gesture
Industrial Robotic Arm – Controlled by Hand Gestures
Project Progress Report
Project Overview
The Industrial Robotic Arm project aims to design and develop a fully functional robotic arm controlled by hand gestures. The arm is built with multiple degrees of freedom using MG966R servo motors, controlled via an ESP32 microcontroller. A wearable glove, equipped with flex sensors and MPU6050 accelerometers, detects hand gestures and sends signals to the robotic arm for corresponding movements. Additionally, the arm can be controlled remotely via a mobile app using the ESP32’s Wi-Fi functionality.
Project Timeline
July 7, 2024 – Start of Project
The project officially began with two main tasks:
- Circuit Simulation: Initial control logic simulations were run to validate the robotic arm's performance, particularly focusing on smooth servo motor control.
- CAD Modeling: A 3D model of the robotic arm was designed, ensuring that the servo motors would fit perfectly. This phase also laid the groundwork for future mechanical assemblies.
July 15-20, 2024 – Design Finalization & Simulation Testing
- CAD Model Refinement: The robotic arm’s 3D model was fine-tuned for optimal movement and motor placement.
- Simulation Testing: Electronic simulations were conducted to ensure that the control signals sent from the Arduino Uno would be accurately interpreted by the servo drivers. Torque calculation issues for the joints were addressed by adjusting motor specifications and redesigning the joints for better load handling.
July 30, 2024 – Components Purchased & Initial Electronics Work
Core electronic components were acquired:
- Six MG966R servo motors
- Arduino Uno
- Servo drivers
- Wi-Fi module (ESP32)
Initial motor control testing with the Arduino revealed minor connectivity issues with the Wi-Fi module, which were eventually resolved by upgrading the power supply and reconfiguring the module for better signal strength.
August 1-10, 2024 – Continued Electronics Assembly & Testing
The focus during this period was on the control circuits and motor synchronization:
- Control Circuits: Each motor was connected to the Arduino via servo drivers and tested to ensure smooth, jitter-free movement.
- Motor Synchronization: Special attention was given to the wrist and elbow joints, ensuring that their movements were synchronized and precise.
August 19, 2024 – Additional Component Purchases
Additional necessary components were purchased:
- Flex sensors for the glove
- MPU6050 accelerometers
- Ball bearings and fasteners
These components were crucial for achieving accurate gesture detection and smooth mechanical movements.
August 25, 2024 – 3D Printing Completed
3D printing of the robotic arm’s components, done using PLA filament, was successfully completed after 30-40 hours of cumulative print time on Creality Ender 3 and Creality Smart 10 Pro printers. Post-processing adjustments were minimal, and the printed parts were ready for assembly.
August 26-28, 2024 – Assembly of Robotic Arm
- Mechanical Assembly: The servo motors were fitted into their respective joints, secured with fasteners and ball bearings to ensure smooth motion.
- Preliminary Motion Tests: The assembly was successfully completed, and basic movement tests verified that all joints responded correctly to control signals.
September 1-5, 2024 – Electronic Circuit & Servo Motor Testing
- Circuit Testing: The focus was on refining the electronic circuits to improve signal flow.
- Motor Performance: The servo motors, particularly those controlling the wrist and elbow joints, were tested for smooth and precise movement. The system showed excellent responsiveness during these tests.
September 5-15, 2024 – Base and Arm Testing & Optimization
- Calibration: The servo motors were calibrated for the base and arm movements.
- Optimization: Adjustments were made to ensure smooth, accurate operation. The robotic arm was fully assembled and calibrated, ready for integration with the glove control system.
Current Status
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ESP32 Control: The robotic arm is now fully operational and can be controlled using a IP address via the ESP32’s Wi-Fi capability.
Robotic arm wokring -
Glove Integration: The glove setup, including the flex sensors and accelerometers, has been completed. Accurate readings from the glove are being captured, allowing gesture detection.
Accelerometer working -
Pending Task: The final challenge is to establish a reliable connection between the glove and the robotic arm for real-time gesture-based control. Once this connection is achieved, the project will be fully functional.
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Progressive Testing: Many testing with the robotic arm and the gloves has been done to make it wokr accoridng to proper calibration
Challenges Faced
1. Wi-Fi Connectivity Issues
During the initial setup, the Wi-Fi module (ESP32) faced connectivity problems, making it difficult to establish a stable connection between the mobile IP page and the robotic arm. After troubleshooting, the issue was traced back to the power supply and signal interference. By upgrading the power supply and reconfiguring the module for better signal strength, the Wi-Fi connection became more stable and reliable.
2. Torque Calculation and Joint Design
One of the early challenges was calculating the required torque for the robotic arm’s joints. The initial design led to insufficient torque, causing difficulty in moving the arm. I addressed this by adjusting the motor specifications and redesigning the joints to distribute the load more efficiently.
3. 3D Printing Delays
The 3D printing process took longer than expected due to printer availability and occasional breakdowns. This delayed the assembly phase. However, the components were eventually printed successfully, with only minor adjustments needed.
4. Servo Motor Jitter
While testing the servo motors, I encountered jittery movements, particularly in the wrist and elbow joints. After troubleshooting, I found that optimizing the power supply and using a higher-quality servo driver significantly reduced the jitter, resulting in smooth motor operation.
5. Establishing a Reliable Glove-Robotic Arm Communication
Although the glove setup is complete and working well in terms of gesture detection, the final barrier is establishing a stable and seamless communication link between the glove and the robotic arm. This remains the last major hurdle to overcome.
Next Steps
- Glove-to-Robotic Arm Communication: Work is underway to establish seamless communication between the glove (ESP32-based) and the robotic arm. Once this is achieved, the robotic arm will be fully controlled by hand gestures, completing the project.
Project Completion Estimate
The project is currently in its final stage, with the remaining task being the integration of the glove with the robotic arm. Once the communication is fully functional, the project will be ready for testing and final demonstrations.